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Lockout Tagout Pocket Guide: One Genium Plaza Schenectady, NY 12304-4690 USA
Lockout Tagout Pocket Guide: One Genium Plaza Schenectady, NY 12304-4690 USA
TAGOUT
POCKET GUIDE
Published and Distributed by
Author
John V. Conforti
Editor
Robert A. Roy
Copyright 1993
by Genium Publishing Corporation
All Rights Reserved
ISBN 0-931690-59-5
Printed in the United States of America
Table of Contents
TABLE OF CONTENTS
I. Introduction .....................................
Review of the Law ............................
Training ..........................................
Periodic Inspection ............................
5
6
7
7
27
27
27
29
29
30
32
34
36
41
43
44
44
46
49
50
52
53
VII. Summary......................................... 55
VIII. Glossary .......................................... 57
Genium Publishing
I. Introduction
I. INTRODUCTION
Slick the Pick Wilson is what my friends call me.
Theres not a lock I cant pick from Juniors school
locker to the doors at the bank I've done em all.
Now, dont get me wrong, its all done on the square.
I'm a master locksmith just like my father and his
father before him. Ive got my college degree, and my
business now has 15 employees. My customers, who
call me Mr. Wilson, or just Freddy, range from
private individuals to major corporations. You see, I
not only reunite forgetful motorists with their car
keys, I help design systems that are used to secure or
isolate energy sources on process equipment. Lets
say you have a broken machine to fix in your plant.
You turn off the power to it and you fix it. Right?
But what happens if youve got your fingers in the
thing and somebody turns it back on. Ouch! Thats
why its smart to tag out critical electrical switches
with a sign that says to leave the switch OFF. To be
even more safe, you can put a lock on the switch.
Thats called a lock out.
And thats why youre reading this now. Your
employer wants you to be aware of the
requirements for locking-out or tagging-out
(controlling) energy sources during servicing and/or
maintaining of machines and equipment. What
requirements? Why the requirements that are spelled
out in the Occupational Safety and Health Standard
1910.147, entitled The Control of Hazardous Energy
(lockout/tagout). And who better to walk and talk
you through it than me, Slick the Pick Wilson?
Well look at the Standard and see how its designed
to help keep you safe from the potential hazards posed
by machines and equipment.
Well discuss the various types of energy sources and
how to keep them from harming you. And, we'll look
at a typical energy-control program, including lockout
vs. tagout along with lockout/tagout equipment. And
we'll discuss the requirements for training and
retraining to keep you sharp and safe.
Well see how to apply the program both to
lockout/tagout procedures and finally, to procedures
for restoring power.
Genium Publishing
Genium Publishing
Genium Publishing
V. ENERGY-CONTROL
SITUATIONS NOT REQUIRING
DOCUMENTED PROCEDURES
And thats the procedure Gee Whiz manufacturing
Company uses to control and lockout the energy
source for the old Spin Deluxe 2200 Mixer. Pretty
straightforward wasnt it?
But, you say, The shift I work on is even simpler
all I gotta do is pull a plug. Well, now, youd think
that anyone would be able to figure out that method
of energy control. I know what you mean. But, you
still have to have a written Energy Control Program,
no matter what. A documented procedure like the one
at Gee Whiz Manufacturing Company may not be
needed. But, and this is a big but, all the following
eight conditions must be met by the employer before
any employees drop documenting a procedure for a
given machine or piece of equipment:
1) No stored (potential) or residual energy The
machines or equipment must not have any
hidden energy sources that are going to come
up and bite you. You remember things like
springs, capacitors, etc.
2) Single energy source Like that plug you
mentioned, youve got to have a single, readily
identifiable, easy-to-isolate, energy source.
3) Complete isolation That simple energy
source, once locked up (like with one of the
plug-type locks you saw earlier), must
completely deenergize and deactivate the
machine or equipment.
4) Isolated lockout The machine or equipment
must still be isolated and locked out during
service or maintenance. Remember, just because
its simple, doesnt make it any less dangerous.
5) Single lockout device If you only have a
simple, single source of energy, then you
should only need one lock, right?
6) Control The lockout device must be in the
control of the authorized employee doing the
repair or service.
44
Genium Publishing
VI. Training
VI. TRAINING
Now I know I dont have to tell you again about how
important it is to have a comprehensive, effective
Energy Control Program and Energy Control
Procedures that are a part of that program. But, youll
remember that theres another equally important part
of the Energy Control Program, training. And the
Occupational Safety and Health Administration
(OSHA), which is responsible for enforcing the
Standard, says, and I quote, OSHA considers these
training requirements to be of critical importance in
helping to ensure that the applicable provisions of the
hazardous energy control procedures are known,
understood, and strictly adhered to by employees.
Need I say more? I dont think so.
But who gets trained on what? Well, its broken down
into three employee groups. They are, in descending
order of required knowledge:
Authorized Employee If you are an
authorized employee, youre the person who
will physically be performing the
lockout/tagout and servicing of the machine or
equipment. So you better know it all.
Affected Employee If you fall under this
category, you may be the person who operates
the machine or equipment on which servicing or
maintenance is being performed. Or perhaps
your job requires you to be in the area in which
servicing or maintenance is being performed.
Other Employee I know it doesnt sound
like much of a title, but it simply means you
work in an area of the plant other than where
maintenance or service is being performed on
the deenergized machine or equipment.
A. Training Requirements
Lets take a look at the what, when, and why (I like
to call them the three Ws ) of training for each
employee:
Authorized Employee
What ? Complete knowledge of Energy Control
Procedures including, but not limited to:
Hazardous energy recognition
Genium Publishing
53
VII. Summary
VII. SUMMARY
Well, folks, thats about all old Slick has got to tell
you about lockout/tagout. Dare I repeat myself and
say that a lock or tag by itself just isnt goin to do
you any good. Its the proper isolation of the
equipment from the energy source, following
established procedures and training that will keep you
going strong and long.
Anyway, let me leave you with the final ten of
Slicks Picks. Keep em with you; it might help jog
your memory:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
59
VIII. Glossary
VIII. GLOSSARY
Affected Employee An employee whose job
requires him/her to operate or use a machine or
equipment on which servicing or maintenance is
being performed under lockout or tagout, or whose
job requires him/her to work in an area in which such
servicing or maintenance is being performed.
Authorized Employee A person who locks out or
tags out machines or equipment in order to perform
servicing or maintenance on those machines or
equipment. An affected employee becomes an
authorized employee when that employees duties
include performing servicing or maintenance covered
under this section.
Capable of being locked out An energy-isolating
device is capable of being locked out if it has a hasp
or other means of attachment to which, or through
which, a lock can be affixed, or it has a locking
mechanism built into it. Other energy-isolating
devices are capable of being locked out if lockout can
be achieved without the need to dismantle, rebuild, or
replace the energy-isolating device or permanently
alter its energy-control capability.
Cutout Box An enclosure designed for surface
mounting and having swinging doors or covers
secured directly to and telescoping with the walls
of the box proper.
Energized Connected to an energy source or
containing residual or stored energy.
Energy Control Procedure Written instructions
adopted by the employer that describe how equipment
and procedures are to be shut down for lockout/tagout
and later released from lockout/tagout for safe startup.
Energy Control Program A safety program adopted
by the employer that includes energy control procedures plus provisions for inspecting the procedures
and training employees for lockout/tagout.
Energy Isolating Device A mechanical device that
physically prevents the transmission or release of
energy, including but not limited to the
following: a manually operated electrical circuit
Genium Publishing
61
Table of Contents
TABLE OF CONTENTS
I. Introduction .....................................
Review of the Law ............................
Training ..........................................
Periodic Inspection ............................
5
6
7
7
27
27
27
29
29
30
32
34
36
41
43
44
44
46
49
50
52
53
VII. Summary......................................... 55
VIII. Glossary .......................................... 57
Genium Publishing
I. INTRODUCTION
Slick the Pick Wilson is what my friends call me.
Theres not a lock I cant pick from Juniors school
locker to the doors at the bank I've done em all.
Now, dont get me wrong, its all done on the square.
I'm a master locksmith just like my father and his
father before him. Ive got my college degree, and my
business now has 15 employees. My customers, who
call me Mr. Wilson, or just Freddy, range from
private individuals to major corporations. You see, I
not only reunite forgetful motorists with their car
keys, I help design systems that are used to secure or
isolate energy sources on process equipment. Lets
say you have a broken machine to fix in your plant.
You turn off the power to it and you fix it. Right?
But what happens if youve got your fingers in the
thing and somebody turns it back on. Ouch! Thats
why its smart to tag out critical electrical switches
with a sign that says to leave the switch OFF. To be
even more safe, you can put a lock on the switch.
Thats called a lock out.
And thats why youre reading this now. Your
employer wants you to be aware of the
requirements for locking-out or tagging-out
(controlling) energy sources during servicing and/or
maintaining of machines and equipment. What
requirements? Why the requirements that are spelled
out in the Occupational Safety and Health Standard
1910.147, entitled The Control of Hazardous Energy
(lockout/tagout). And who better to walk and talk
you through it than me, Slick the Pick Wilson?
Well look at the Standard and see how its designed
to help keep you safe from the potential hazards posed
by machines and equipment.
Well discuss the various types of energy sources and
how to keep them from harming you. And, we'll look
at a typical energy-control program, including lockout
vs. tagout along with lockout/tagout equipment. And
we'll discuss the requirements for training and
retraining to keep you sharp and safe.
Genium Publishing
Genium Publishing
Property Tag #:
12745
Work to be performed:
Authorized Employee
Responsible:
Blade Alignment .
John Smith
name (print)/signature/date
Affected Employees:
Name:
J. Jones
Job Title: Mixer
K. Smith
Bagger
B. Barnes
Quality
Control
Hazard
Method of Control
Kinetic
Electric
440 Volts
energy control
Others
None
OFF Button
Control Panel
Blade lockout
Control panel
Genium Publishing
U-Joint
Between main
drive shaft/output shaft
Check
[X]
[X]
[X]
Present
Method of
Restraint
No
No
No
No
No
No
No
No
No
No
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Dissipation
Check
[X]
[X]
[X]
Remarks
.
Date
Genium Publishing
V. ENERGY-CONTROL
SITUATIONS NOT REQUIRING
DOCUMENTED PROCEDURES
And thats the procedure Gee Whiz manufacturing
Company uses to control and lockout the energy
source for the old Spin Deluxe 2200 Mixer. Pretty
straightforward wasnt it?
But, you say, The shift I work on is even simpler
all I gotta do is pull a plug. Well, now, youd think
that anyone would be able to figure out that method
of energy control. I know what you mean. But, you
still have to have a written Energy Control Program,
no matter what. A documented procedure like the one
at Gee Whiz Manufacturing Company may not be
needed. But, and this is a big but, all the following
eight conditions must be met by the employer before
any employees drop documenting a procedure for a
given machine or piece of equipment:
1) No stored (potential) or residual energy The
machines or equipment must not have any
hidden energy sources that are going to come
up and bite you. You remember things like
springs, capacitors, etc.
2) Single energy source Like that plug you
mentioned, youve got to have a single, readily
identifiable, easy-to-isolate, energy source.
3) Complete isolation That simple energy
source, once locked up (like with one of the
plug-type locks you saw earlier), must
completely deenergize and deactivate the
machine or equipment.
4) Isolated lockout The machine or equipment
must still be isolated and locked out during
service or maintenance. Remember, just because
its simple, doesnt make it any less dangerous.
5) Single lockout device If you only have a
simple, single source of energy, then you
should only need one lock, right?
6) Control The lockout device must be in the
control of the authorized employee doing the
repair or service.
44
Genium Publishing
VI. Training
VI. TRAINING
Now I know I dont have to tell you again about how
important it is to have a comprehensive, effective
Energy Control Program and Energy Control
Procedures that are a part of that program. But, youll
remember that theres another equally important part
of the Energy Control Program, training. And the
Occupational Safety and Health Administration
(OSHA), which is responsible for enforcing the
Standard, says, and I quote, OSHA considers these
training requirements to be of critical importance in
helping to ensure that the applicable provisions of the
hazardous energy control procedures are known,
understood, and strictly adhered to by employees.
Need I say more? I dont think so.
But who gets trained on what? Well, its broken down
into three employee groups. They are, in descending
order of required knowledge:
Authorized Employee If you are an
authorized employee, youre the person who
will physically be performing the
lockout/tagout and servicing of the machine or
equipment. So you better know it all.
Affected Employee If you fall under this
category, you may be the person who operates
the machine or equipment on which servicing or
maintenance is being performed. Or perhaps
your job requires you to be in the area in which
servicing or maintenance is being performed.
Other Employee I know it doesnt sound
like much of a title, but it simply means you
work in an area of the plant other than where
maintenance or service is being performed on
the deenergized machine or equipment.
A. Training Requirements
Lets take a look at the what, when, and why (I like
to call them the three Ws ) of training for each
employee:
Authorized Employee
What ? Complete knowledge of Energy Control
Procedures including, but not limited to:
Hazardous energy recognition
Genium Publishing
53
VII. Summary
VII. SUMMARY
Well, folks, thats about all old Slick has got to tell
you about lockout/tagout. Dare I repeat myself and
say that a lock or tag by itself just isnt goin to do
you any good. Its the proper isolation of the
equipment from the energy source, following
established procedures and training that will keep you
going strong and long.
Anyway, let me leave you with the final ten of
Slicks Picks. Keep em with you; it might help jog
your memory:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
59
VIII. Glossary
VIII. GLOSSARY
Affected Employee An employee whose job
requires him/her to operate or use a machine or
equipment on which servicing or maintenance is
being performed under lockout or tagout, or whose
job requires him/her to work in an area in which such
servicing or maintenance is being performed.
Authorized Employee A person who locks out or
tags out machines or equipment in order to perform
servicing or maintenance on those machines or
equipment. An affected employee becomes an
authorized employee when that employees duties
include performing servicing or maintenance covered
under this section.
Capable of being locked out An energy-isolating
device is capable of being locked out if it has a hasp
or other means of attachment to which, or through
which, a lock can be affixed, or it has a locking
mechanism built into it. Other energy-isolating
devices are capable of being locked out if lockout can
be achieved without the need to dismantle, rebuild, or
replace the energy-isolating device or permanently
alter its energy-control capability.
Cutout Box An enclosure designed for surface
mounting and having swinging doors or covers
secured directly to and telescoping with the walls
of the box proper.
Energized Connected to an energy source or
containing residual or stored energy.
Energy Control Procedure Written instructions
adopted by the employer that describe how equipment
and procedures are to be shut down for lockout/tagout
and later released from lockout/tagout for safe startup.
Energy Control Program A safety program adopted
by the employer that includes energy control procedures plus provisions for inspecting the procedures
and training employees for lockout/tagout.
Energy Isolating Device A mechanical device that
physically prevents the transmission or release of
energy, including but not limited to the
following: a manually operated electrical circuit
Genium Publishing
61